Intake air heating system of combined cycle plant

ABSTRACT

A gas turbine  2  is driven by a combustion gas produced when BFG compressed by a gas compressor  5  and air compressed by a compressor  1  are burned in a combustor  7.  Steam is generated from a waste heat boiler  8  by utilization of heat of an exhaust gas from the gas turbine  2,  and a steam turbine  4  is driven by this steam. An electric generator  3  generates electricity upon driving of the turbines  2  and  4.  A condensing heat exchanger  20  is disposed in an air intake duct  6,  and part of steam from the waste heat boiler  8  is flowed through the heat exchanger  20  to heat intake air. The amount of steam flowed through the heat exchanger  20  is adjusted by the adjustment of the degree of opening of a steam control valve  22  by a control device  40.  By so doing, the ignition performance of the gas turbine in a BFG-fired gas turbine combined cycle plant is enhanced even in an extremely cold district.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to an intake air heating system of a combinedcycle plant, which is designed, particularly, to be operable even in anextremely cold district.

2. Description of the Related Art

In an iron making process, a large amount of BFG (blast furnace gas) isformed in a blast furnace. In recent years, a BFG-fired combined cycleplant, which uses this BFG as a fuel for a gas turbine, has attractedattention from the viewpoints of environmental protection and effectiveutilization of energy.

BFG is in a special fuel state such that it has a lower calorific valueand contains larger amounts of impurities in the fuel, than a naturalgas which is usually used as a gas turbine fuel.

In the BFG-fired combined cycle plant, therefore, BFG is used as a fuel,with various ideas including, for example, the idea that BFG iscompressed in a gas compressor directly connected to a gas turbineshaft, and then burned in a combustor.

The installation of such a BFG-fired combined cycle plant in anextremely cold district as well as in a warm region is underconsideration.

In installing the BFG-fired combined cycle plant in the extremely colddistrict, the following problems occur, because the calorific value ofBFG is low and the air temperature of the atmosphere taken in is verylow (e.g., −30° C.)

(1) The Ignition Performance of the Gas Turbine Deteriorates.

That is, under extremely low atmospheric temperature (e.g., −30° C.)conditions, it becomes difficult to ignite the gas turbine.

(2) Combustion Vibrations in a No-Load State are Apt to Occur.

That is, under extremely low atmospheric temperature (e.g., −30° C.)conditions, combustion vibrations tend to occur at an increased turbinespeed or in a state close to a no-load state. At the increased turbinespeed or in a low-load state, therefore, it becomes difficult to make anadjustment so that combustion vibrations do not occur.

(3) Freezing or Icing of Moisture in Intake Air at the Inlet of theCompressor Occurs.

If the temperature of the air taken in is low, moisture in the lowtemperature air has a possibility to freeze or ice at the inlet of thecompressor.

Thus, an anti-icing technology, which bleeds part of air in the casingof the compressor, and incorporates the bleed air into intake air toheat the intake air, has already been developed. With this technology,however, air within the casing of the compressor is bled. Thus,combustibility is adversely affected, and a large amount of air cannotbe bled, so that the range of a rise in the intake air temperature hasbeen restricted.

Even if such a technology is applied to the BFG-fired combined cycleplant installed in the extremely cold district, it is impossible toensure the amount of heating bleed air required for heating air at anextremely low temperature (e.g., −30° C.), because of limitations on theamount of bleed air.

(4) Surging is Apt to Occur in the Air Compressor Under Load in theVicinity of Rated Load.

That is, under extremely low atmospheric temperature (e.g., −30° C.)conditions, surging is apt to occur under constant load. Thus, thecompressor is operated in a limited manner so as not to cause surging.This requires limitations on load, thereby ma king operation under heavyload difficult.

SUMMARY OF THE INVENTION

The present invention has been accomplished in light of theabove-described conventional technologies. It is an object of theinvention to provide an intake air heating system of a combined cycleplant using a gas of low calorific value, for example, BFG, as a fuel,the intake air heating system being capable of effectively heatingintake air at an extremely low temperature, without adversely affectingcombustibility.

A feature of the present invention for solving the above-mentionedproblems is an intake air heating system of a combined cycle plantincluding

a compressor for compressing intake air taken in via an air intake duct,

a combustor for burning compressed air compressed by the compressor anda fuel gas,

a gas turbine driven by a combustion gas obtained by combustion in thecombustor,

a waste heat boiler for recovering heat in an exhaust gas dischargedfrom the gas turbine to generate steam,

a steam turbine driven by steam generated by the waste heat boiler, and

a condenser for condensing exhaust steam discharged from the steamturbine into water,

the intake air heating system comprising:

a heat exchanger disposed in the air intake duct; and

a heating medium flow-through structure for flowing steam, which hasbeen generated in the waste heat boiler, through the heat exchanger, andalso returning water, which has been discharged from the heat exchanger,to the condenser.

Another feature of the present invention is an intake air heating systemof a combined cycle plant including

a compressor for compressing intake air taken in via an air intake duct,

a gas compressor for compressing a fuel gas,

a combustor for burning compressed air compressed by the compressor andthe fuel gas compressed by the gas compressor,

a gas turbine driven by a combustion gas obtained by combustion in thecombustor,

a waste heat boiler for recovering heat in an exhaust gas dischargedfrom the gas turbine to generate steam,

a steam turbine driven by steam generated by the waste heat boiler, and

a condenser for condensing exhaust steam discharged from the steamturbine into water,

the intake air heating system comprising:

a heat exchanger disposed in the air intake duct; and

a heating medium flow-through structure for flowing steam, which hasbeen generated in the waste heat boiler, through the heat exchanger, andalso returning water, which has been discharged from the heat exchanger,to the condenser.

Another feature of the present invention is an intake air heating systemof a combined cycle plant including

a compressor for compressing intake air taken in via an air intake duct,

a gas compressor for compressing a fuel gas,

a combustor for burning compressed air compressed by the compressor andthe fuel gas compressed by the gas compressor,

a gas turbine driven by a combustion gas obtained by combustion in thecombustor,

a waste heat boiler for recovering heat in an exhaust gas dischargedfrom the gas turbine to generate steam,

a steam turbine driven by steam generated by the waste heat boiler, and

a condenser for condensing exhaust steam discharged from the steamturbine into water,

the intake air heating system comprising:

a heat exchanger disposed in the air intake duct;

a steam supply pipe for supplying steam generated in the waste heatboiler to the heat exchanger;

a steam control valve interposed in the steam supply pipe;

a return pipe for returning water discharged from the heat exchanger tothe condenser;

a temperature detector for detecting a temperature of intake air takeninto the compressor; and

a control device for adjusting a degree of opening of the steam controlvalve so that the temperature detected by the temperature detectorbecomes a preset temperature.

Another feature of the present invention is an intake air heating systemof a combined cycle plant including

a compressor for compressing intake air taken in via an air intake duct,

a gas compressor for compressing a fuel gas,

a combustor for burning compressed air compressed by the compressor andthe fuel gas compressed by the gas compressor,

a gas turbine driven by a combustion gas obtained by combustion in thecombustor,

a waste heat boiler for recovering heat in an exhaust gas dischargedfrom the gas turbine to generate steam,

a steam turbine driven by steam generated by the waste heat boiler, and

a condenser for condensing exhaust steam discharged from the steamturbine into water,

the intake air heating system comprising:

a heat exchanger disposed in the air intake duct;

a steam supply pipe for supplying steam generated in the waste heatboiler to the heat exchanger;

a steam control valve interposed in the steam supply pipe;

a return pipe for returning water discharged from the heat exchanger tothe condenser;

a drain tank interposed in the return pipe, and a water level controlvalve which is disposed in the return pipe nearer the condenser than isthe drain tank;

a temperature detector for detecting a temperature of intake air takeninto the compressor;

a water level detector for detecting a water level within the draintank; and

a control device for adjusting a degree of opening of the steam controlvalve so that the temperature detected by the temperature detectorbecomes a preset temperature, and also adjusting a degree of opening ofthe water level control valve so that the water level detected by thewater level detector becomes a set water level which has been setbeforehand.

Another feature of the present invention is the intake air heatingsystem characterized in that the fuel gas is a low-calorie fuel such asBFG (blast furnace gas).

According to the present invention, the heat exchanger is disposed inthe air intake duct, and part of steam generated by the waste heatboiler is flowed through the heat exchanger, whereby intake air isheated. Thus, even extremely low temperature intake air can beeffectively heated.

Since the effective heating of intake air can be achieved as describedabove, an improvement in the ignition performance of the gas turbine(ease of ignition), the prevention of combustion vibrations, and theprevention of icing and surging can be realized.

Hence, it becomes possible to operate the combined cycle plant, whichutilizes a fuel gas of low calorific value, such as BFG, even in anextremely cold district.

Furthermore, only part of steam from the waste heat boiler is utilizedfor the heating of intake air. Thus, the system of the present inventiondoes not adversely affect the combustion performance of the gas turbine,in comparison with an anti-icing system using gas turbine casing air.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a system diagram showing a combined cycle plant according toan embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The best mode for carrying out the present invention will be describedin detail based on its embodiment.

FIG. 1 is a system diagram showing a BFG-fired combined cycle accordingto an embodiment of the present invention.

In the present embodiment, a compressor 1, a gas turbine 2, an electricgenerator 3, a steam turbine 4, and a gas compressor 5 are provided onthe same rotating shaft.

Compressed air, obtained when intake air taken in via an air intake duct6 is compressed by the compressor 1, and BFG compressed by the gascompressor 5 are burned in a combustor 7. The gas turbine 2 is driven bya combustion gas formed by this combustion. An exhaust gas dischargedfrom the gas turbine 2 has its heat recovered by a waste heat boiler 8,and steam is generated in the waste heat boiler 8. The exhaust gashaving the heat recovered by the waste heat boiler 8 is discharged froma smokestack 9.

Steam generated by the waste heat boiler 8 is sent to the steam turbine4 to drive the steam turbine 4. Exhaust steam discharged from the steamturbine 4 is cooled in a condenser 10 for condensation. The resultingcondensate water receives heat from the waste heat boiler 8 to becomesteam again, and the steam is sent to the steam turbine 4. The numeral11 denotes an economizer, the numeral 12 denotes an evaporator, and thenumeral 13 denotes a superheater.

The foregoing explanations are the same as those for the conventionalBFG-fired combined cycle plant.

In the present embodiment, a heat exchanger 20 is further provided inthe air intake duct 6, concretely, in a portion of the air intake duct 6where an air intake filter is provided (a portion downstream of the airintake filter).

Steam (own boiler steam) generated in the waste heat boiler 8 issupplied to the heat exchanger 20 via a steam supply pipe 21. Thesupplied steam flows through the interior of the heat exchanger 20 toheat intake air flowing through the air duct 6. The heat exchanger 20 isa non-contact heat exchanger where steam and intake air do not directlycontact.

A steam control valve 22 is interposed in the steam supply pipe 21.

When the own boiler steam is not generated, i.e., when the steam fromthe waste heat boiler 8 is not generated, auxiliary steam is suppliedfrom an auxiliary steam source (not shown) to the heat exchanger 20 viaan auxiliary steam supply pipe 23.

An auxiliary steam control valve 24 is interposed in the auxiliary steamsupply pipe 23.

In the present embodiment, steam supplied to the heat exchanger 20 flowswithin the heat exchanger 20, whereby the steam becomes condensed andturns into water. That is, the heat exchanger 20 functions as acondensing heat exchanger, which also utilizes the heat of condensationpossessed by steam to heat intake air. Thus, its heating efficiency ishigh.

If the own boiler steam is supplied to the heat exchanger 20, theresulting condensate water upon passage through the heat exchanger 20 isreturned to the condenser 10 via a return pipe 25.

In the return pipe 25, a drain tank 26 is interposed on the side of theheat exchanger 20, and a water level control valve (return side) 27 isinterposed on the side of the condenser 10.

If the auxiliary steam is supplied to the heat exchanger 20, theresulting condensate water upon passage through the heat exchanger 20 isdischarged to the outside via an atmospheric escape pipe 28.

A water level control valve (atmospheric escape side) 29 is interposedin the atmospheric escape pipe 28.

In the air intake duct 6, a temperature detector 30 for detecting thetemperature of intake air taken into the compressor 1 is provided. Thedetected temperature detected by the temperature detector 30 is sent toa control device 40.

The drain tank 26 is equipped with a water level detector 31 fordetecting the water level of water accumulated in the drain tank 26. Thedetected water level detected by the water level detector 31 is sent tothe control device 40.

The control device 40 controls the opening and closing of each of thevalves 22, 24, 27 and 29, and the degree of opening of each of thesevalves. A control technique by the control device 40 will be describednext.

<Heating of Intake Air by Own Boiler Steam>

In this case, the control device 40 exercises valve control as describedbelow.

First, the auxiliary steam control valve 24 and the water level controlvalve (atmospheric escape side) 29 are fully closed.

In this state, the degree of opening of the steam control valve 22 isadjusted so that the temperature of intake air detected by thetemperature detector 30 becomes a temperature set beforehand (e.g., 5°C.). By so adjusting the degree of opening of the steam control valve 22to adjust the amount of steam flowed into the heat exchanger 20, thedegree of heating the intake air is adjusted. As a result, thetemperature of air taken into the compressor 1 can be effectively heatedto the set temperature.

In this case, the heat exchanger 20 functions as the condensing heatexchanger in accordance with the temperature balance between thetemperature of intake air and the temperature of steam.

Furthermore, it is advisable to detect the pressure of steam supplied,and take this pressure as well into consideration, in addition to thedetected temperature of intake air detected by the temperature detector30, thereby adjusting the degree of opening of the steam control valve22.

That is, the adjustment of the degree of opening of the steam controlvalve 22 based on the temperature of intake air is used as a basis forcontrol. In addition, the following control may also be exercised: Ifthe pressure of steam is high, the degree of opening of the steamcontrol valve 22 is rendered low. If the pressure of steam is low, thedegree of opening of the steam control valve 22 is rendered high.Effecting such types of control together, the degree of opening of thesteam control valve 22 may be adjusted.

Besides, the degree of opening of the water level control valve 27 isadjusted so that the detected water level within the drain tank 26detected by the water level detector 31 becomes a set water level whichhas been set beforehand. By so adjusting the water level, only waterreturns to the condenser 10, and steam can be prevented from returningthere.

<Heating of Intake Air by Auxiliary Steam>

In this case, the control device 40 exercises valve control as describedbelow.

First, the steam control valve 22 and the water level control valve 27are fully closed.

In this state, the degree of opening of the auxiliary steam controlvalve 24 is adjusted so that the temperature of intake air detected bythe temperature detector 30 becomes a temperature set beforehand (e.g.,5° C.). By so adjusting the degree of opening of the auxiliary steamcontrol valve 24 to adjust the amount of steam flowed into the heatexchanger 20, the degree of heating the intake air is adjusted. As aresult, the temperature of air taken into the compressor 1 can beeffectively heated to the set temperature.

In this case, the heat exchanger 20 functions as the condensing heatexchanger in accordance with the temperature balance between thetemperature of intake air and the temperature of steam.

Furthermore, it is advisable to detect the pressure of steam supplied,and take this pressure as well into consideration, in addition to thedetected temperature of intake air detected by the temperature detector30, thereby adjusting the degree of opening of the auxiliary steamcontrol valve 24.

That is, the adjustment of the degree of opening of the auxiliary steamcontrol valve 24 based on the temperature of intake air is used as abasis for control. In addition, the following control may also beexercised: If the pressure of steam is high, the degree of opening ofthe auxiliary steam control valve 24 is rendered low. If the pressure ofsteam is low, the degree of opening of the auxiliary steam control valve24 is rendered high. Effecting such types of control together, thedegree of opening of the auxiliary steam control valve 24 may beadjusted.

Besides, the degree of opening of the water level control valve 29 isadjusted so that the detected water level within the drain tank 26detected by the water level detector 31 becomes a set water level whichhas been set beforehand.

The present invention can be applied not only to a BFG-fired combinedcycle plant, but also to a combined cycle plant using a gas of lowcalorific value as a fuel.

1. An intake air heating system of a combined cycle plant including acompressor for compressing intake air taken in via an air intake duct, acombustor for burning compressed air compressed by the compressor and afuel gas, a gas turbine driven by a combustion gas obtained bycombustion in the combustor, a waste heat boiler for recovering heat inan exhaust gas discharged from the gas turbine to generate steam, asteam turbine driven by steam generated by the waste heat boiler, and acondenser for condensing exhaust steam discharged from the steam turbineinto water, the intake air heating system comprising: a heat exchangerdisposed in the air intake duct; and a heating medium flow-throughstructure for flowing steam, which has been generated in the waste heatboiler, through the heat exchanger, and also returning water, which hasbeen discharged from the heat exchanger, to the condenser.
 2. An intakeair heating system of a combined cycle plant including a compressor forcompressing intake air taken in via an air intake duct, a gas compressorfor compressing a fuel gas, a combustor for burning compressed aircompressed by the compressor and the fuel gas compressed by the gascompressor, a gas turbine driven by a combustion gas obtained bycombustion in the combustor, a waste heat boiler for recovering heat inan exhaust gas discharged from the gas turbine to generate steam, asteam turbine driven by steam generated by the waste heat boiler, and acondenser for condensing exhaust steam discharged from the steam turbineinto water, the intake air heating system comprising: a heat exchangerdisposed in the air intake duct; and a heating medium flow-throughstructure for flowing steam, which has been generated in the waste heatboiler, through the heat exchanger, and also returning water, which hasbeen discharged from the heat exchanger, to the condenser.
 3. An intakeair heating system of a combined cycle plant including a compressor forcompressing intake air taken in via an air intake duct, a gas compressorfor compressing a fuel gas, a combustor for burning compressed aircompressed by the compressor and the fuel gas compressed by the gascompressor, a gas turbine driven by a combustion gas obtained bycombustion in the combustor, a waste heat boiler for recovering heat inan exhaust gas discharged from the gas turbine to generate steam, asteam turbine driven by steam generated by the waste heat boiler, and acondenser for condensing exhaust steam discharged from the steam turbineinto water, the intake air heating system comprising: a heat exchangerdisposed in the air intake duct; a steam supply pipe for supplying steamgenerated in the waste heat boiler to the heat exchanger; a steamcontrol valve interposed in the steam supply pipe; a return pipe forreturning water discharged from the heat exchanger to the condenser; atemperature detector for detecting a temperature of intake air takeninto the compressor; and a control device for adjusting a degree ofopening of the steam control valve so that the temperature detected bythe temperature detector becomes a preset temperature.
 4. An intake airheating system of a combined cycle plant including a compressor forcompressing intake air taken in via an air intake duct, a gas compressorfor compressing a fuel gas, a combustor for burning compressed aircompressed by the compressor and the fuel gas compressed by the gascompressor, a gas turbine driven by a combustion gas obtained bycombustion in the combustor, a waste heat boiler for recovering heat inan exhaust gas discharged from the gas turbine to generate steam, asteam turbine driven by steam generated by the waste heat boiler, and acondenser for condensing exhaust steam discharged from the steam turbineinto water, the intake air heating system comprising: a heat exchangerdisposed in the air intake duct; a steam supply pipe for supplying steamgenerated in the waste heat boiler to the heat exchanger; a steamcontrol valve interposed in the steam supply pipe; a return pipe forreturning water discharged from the heat exchanger to the condenser; adrain tank interposed in the return pipe, and a water level controlvalve which is disposed in the return pipe nearer the condenser than isthe drain tank; a temperature detector for detecting a temperature ofintake air taken into the compressor; a water level detector fordetecting a water level within the drain tank; and a control device foradjusting a degree of opening of the steam control valve so that thetemperature detected by the temperature detector becomes a presettemperature, and also adjusting a degree of opening of the water levelcontrol valve so that the water level detected by the water leveldetector becomes a set water level which has been set beforehand.
 5. Theintake air heating system of a combined cycle plant according to any oneof claims 2 to 4, wherein the fuel gas is BFG (blast furnace gas).